Product
Virtual Process Plant
Software-based simulation of an industrial plant — real-time monitoring, process testing, and operator training without impacting live operations.
A Digital Twin of Your Process Plant
The Virtual Process Plant is a software application that mirrors the operations of a real industrial plant — modelling each unit, sensor, process parameter, and operational state in software. Instead of connecting to live field instruments, VPP uses simulated sensor values driven by configurable formulas, soft sensors, and process logic.
Operators interact with a SCADA-style interface that looks and behaves exactly like the real plant's HMI — navigating process screens, reading live values, acknowledging alarms, monitoring trending data, and responding to abnormal conditions — but in a completely safe, software-only environment.
The result is an operator training tool, a process testing environment, and a system validation platform — all in one application that can run on-premises or in the cloud, independent of your live production infrastructure.
Deployed: Oil Manufacturing Company, USA
Why Industrial Operations Need a Virtual Process Plant
New operators cannot learn by operating live plant systems — errors have real consequences. VPP provides a training environment where operators can learn the plant layout, understand process behaviour, practice emergency procedures, and develop operational confidence without any risk to production or equipment.
When SCADA configurations, alarm setpoints, or control logic need to be modified, testing on the live system is risky. VPP allows automation engineers to test configuration changes, validate new alarm sequences, and verify control logic in a simulated environment before deploying to the production SCADA.
VPP allows engineers to simulate different operating scenarios, explore process behaviour under varying conditions, and visualize the entire plant workflow from a single interface. For complex process plants with multiple interdependent units, VPP builds operational understanding that is otherwise only gained through years of experience.
Reducing the time from operator hiring to productive operation is a direct operational benefit. VPP provides a structured, self-paced training environment that accelerates the learning curve for new operators — especially in facilities with complex multi-unit processes or seasonal workforce expansion.
What the Ath VPP Delivers
Real-Time Simulation Engine
Simulates live sensor data for all process units in real time. Each virtual sensor maintains a continuous data stream based on configured formulas and operating mode parameters — producing realistic values that respond to simulated process changes and operator actions.
Soft Sensors & Formula-Based Values
Each process parameter is defined by a configurable formula that can reference other sensors, operational modes, time-based functions, or random variation within specified bounds. Administrators can create and modify soft sensor definitions without coding — providing flexible, realistic simulation of process behaviour for any unit operation.
SCADA-Like Operator Interface
The VPP interface is designed to mirror the look and feel of the plant's actual SCADA HMI — using the same process graphics, symbols, navigation structure, and alarm presentation that operators will encounter in the real control room. Familiarity with the VPP interface directly transfers to the live system, reducing retraining time.
Alarm Simulation & Training
Alarms can be triggered based on simulated sensor values exceeding configured limits, or manually injected by a training instructor. Operators practice acknowledging, responding to, and resolving alarm conditions — including abnormal situation management — in the safe environment of the VPP before encountering them in production.
Trending & Historical Data
All simulated process data is logged to a historian in real time. Operators can access trend views showing process parameter history, enabling them to learn how process values evolve over time, understand normal operating ranges, and recognise deviation patterns. Multi-parameter trending with export capabilities.
Two-Tier Role Management
Administrator and Operator roles with distinct access permissions. Administrators can configure the simulation parameters, modify soft sensor formulas, create training scenarios, and inject alarms. Operators access the plant interface within defined permission boundaries — replicating the role separation of a real control room environment.
Cloud or On-Premises Deployment
VPP can be deployed on-premises on your own servers, accessible from any workstation or device on your network, or deployed to cloud infrastructure (Azure, AWS) for remote access by distributed teams. Web-based interface — no desktop client installation required. Accessible from any modern browser.
Process Statistics & Reporting
Operational statistics and reports on simulated process performance — unit availability, production rates, consumption metrics, and alarm frequency. Reports can be used to document training sessions, assess operator performance during simulation exercises, and maintain records for compliance purposes.
VPP at Oil Manufacturing Company, USA
The first commercial deployment of the Ath VPP was delivered for Oil Manufacturing Company, an oil manufacturing company in the USA. The deployment simulates the complete oil production workflow across 15 distinct process sections.
Process Sections Simulated
What the Deployment Includes
Tab-based navigation mirroring the physical plant layout — operators navigate between process sections exactly as in the real HMI.
Full alarm list, acknowledgement, and alarm history — operators learn alarm response procedures safely.
Multi-parameter trending with configurable time ranges. Process statistics dashboard showing production KPIs in real time.
Two-tier role management — Supervisor can configure simulation parameters; Operator accesses plant interface within defined bounds.
Who Benefits from a Virtual Process Plant
New Plants & Greenfield Projects
Train your operations team before the plant is commissioned. Operators learn the process workflow on the VPP while construction and commissioning activities are still ongoing.
Facilities with High Operator Turnover
Reduce new hire onboarding time and operational risk. VPP provides a structured, repeatable training path for every new operator without consuming experienced operators' time for shadowing.
SCADA Migration or Upgrade Projects
When upgrading to a new SCADA or changing the HMI, a VPP allows operators to familiarise with the new interface and workflow before the cutover — reducing disruption and errors at go-live.
Complex Multi-Unit Process Plants
Plants with multiple interdependent processing units benefit from VPP's whole-plant view — operators can understand how upstream changes affect downstream units without running the actual plant through different scenarios.
Emergency Procedure Drills
Administrators can inject abnormal conditions — multiple simultaneous alarms, equipment trip scenarios, process upsets — to drill operators on emergency response procedures in a controlled environment.
SCADA & Control System Testing
Automation engineers use VPP to test and validate SCADA configuration changes, new alarm setpoints, and modified control sequences before deploying to the live system — eliminating production risk from configuration errors.
Common Questions
No. VPP is completely independent of your live production system. All sensor values are simulated by the soft sensor engine based on configurable formulas and process logic. There is no connection to PLCs, DCS, or field instruments. This is by design — it ensures there is zero risk of VPP activity affecting live operations.
Yes. VPP is configured for each deployment based on the client's specific plant layout, process units, equipment, and sensor sets. Our first deployment was for canola oil processing; the platform has been designed to handle any process plant — petroleum terminals, chemical plants, water treatment, food processing, pharmaceutical utilities, or power plant auxiliaries. We scope each VPP deployment based on a detailed review of your plant's P&IDs, HMI screen layouts, and operational philosophy.
The accuracy of soft sensor values depends on how the formulas are configured. We work with your process engineers during the setup phase to define realistic formulas for each sensor — referencing actual operating ranges, inter-parameter relationships, and process dependencies from your operating data. The goal is not exact physical process simulation (as a full dynamic process simulator provides), but rather operationally realistic behaviour that gives operators meaningful training value. For most operator training applications, this level of fidelity is appropriate and cost-effective.
Implementation timeline depends on plant complexity (number of process units, sensor count, number of HMI screens to replicate) and the quality of documentation available. A mid-complexity plant with 8–15 process sections typically takes 10–16 weeks from requirements review to deployment. We start with a detailed scoping discussion where we review your existing HMI screens, P&IDs, and sensor lists to provide an accurate timeline and cost estimate.
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Want a Virtual Process Plant for Your Facility?
Share your plant's process overview, the type of operations you want to simulate, and your primary use case — training, testing, or process understanding. We will assess the scope and provide a cost and timeline estimate.